Method and device for manufacturing slip prevention material of construction machinery

ABSTRACT

The present invention achieves easy manufacturing of a slip stopper that has a great slip stopping effect and can be used for a location where a problem occurs if a though hole is opened therein. After a protruding portion is formed by using a first punching die unit so as to protrude from the upper surface of a steel plate  5  in a plate thickness direction, a concave portion  8  and drain channels  9  are formed in the protruding portion by shear planes that face almost perpendicularly to the steel plate upper surface and have been half-blanked so as not to open a through hole in the steel plate by using a second punching die unit  11 , whereby it becomes possible to readily manufacture an excellent slip stopper.

TECHNICAL FIELD

[0001] The present invention relates to the technical fields of a method and an apparatus for manufacturing a slip stopper employed for a construction machine such as a hydraulic excavator.

BACKGROUND ART

[0002] Generally, a slip stopper with a slip stopping function is occasionally used for floors, passageways, and stairs in building constructions, floors and steps of buses, trucks and special vehicles, decks of railroad vehicles and ships, and scaffolding at construction sites, and as such a slip stopper, for example, a slip stopper shown in FIG. 10 has been conventionally known. This is a so-called striped steel plate that has a plurality of projections 51 molded in continuous patterned shape, and a corresponding slip stopping effect can be expected in the case of normal scaffolding, however, the height of the projections 51 of this striped steel plate is low and curved, so that a more reliable slip stopper is required when workers step on a cover covering the upper surface of a construction machine as a stepping surface during maintenance.

[0003] Therefore, as shown in FIG. 11, a slip stopper for construction machines has been provided in which slip stopping parts 53 having raised edges formed by the marginal portion of a through hole 52 stamped out into a circle shape or a star shape are formed in a running pattern. In this slip stopper, the raised portions of the slip stopping part 53 can be made sufficiently high, and sharp shear planes are formed by means of stamping-out, so that a great slip stopping effect can be obtained.

[0004] If the slip stopper having the through hole stamped out is used as it is as a cover to cover the upper surface of a construction machine, problems such that rainwater or dirt enters the inside of the cover, heated air from an engine blows upward the cover, or noise diffuses are inevitable. Therefore, a double structure in that a flat steel plate is fixed to the lower side of the slip stopper is employed to prevent the abovementioned problems, however, the double structure increases production processes and costs in comparison with the single structure, and further poses a problem in that mud or dust entering from the through hole of the slip stopper accumulates between the slip stopper and the lower side flat steel plate or in the through hole, and makes cleaning difficult. These problems are to be solved by the invention.

DISCLOSURE OF THE INVENTION

[0005] In view of the abovementioned circumstances, the present invention has been developed to solve the abovementioned problems, wherein after a protruding portion is formed on a plate surface of a metal plate so as to protrude in the plate thickness direction, a concave portion is formed in the protruding portion by shear planes which face almost perpendicularly to the plate surface of the metal plate and are obtained by half blanking that does not open a through hole in the metal plate.

[0006] Thereby, a slip stopper which achieves a great slip stopping effect and can be used for a location where a problem occurs if a through hole is opened therein can be easily manufactured.

[0007] Furthermore, the invention comprises a first punching die unit for forming a protruding portion on a plate surface of a metal plate so as to protrude in the plate thickness direction, a second punching die unit for forming a concave portion by shear planes which face almost perpendicularly to the plate surface of the metal plate and are obtained by half blanking that does not open a through hole in the metal plate.

[0008] By using the first and second punching die units, a slip stopper which achieves a great slip stopping effect and can be used for a location where a problem occurs if a through hole is opened therein can be easily manufactured.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a plan view of a construction machine.

[0010]FIG. 2 is a partial plan view of a slip stopper.

[0011]FIG. 3(A) is a plan view of a slip stopping part, FIG. 3(B) is an X-X sectional view of (A), and FIG. 3(C) is a Y-Y sectional view of (A).

[0012]FIG. 4(A) is a perspective plan view of a slip stopping part, and FIG. 4(B) is a perspective bottom view of the slip stopping part.

[0013]FIG. 5 is a sectional view of a first punching die unit when a striker moves up.

[0014]FIG. 6 is a sectional view of the first punching die unit when a striker moves down.

[0015]FIG. 7(A) is a plan view of a protruding portion after a first process is finished, and FIG. 7(B) is an X-X sectional view of (A).

[0016]FIG. 8 is a sectional view of a second punching die unit when a striker moves up.

[0017]FIG. 9 is a sectional view of the second punching die unit when the striker moves down.

[0018]FIG. 10(A) is a plan view of a checkered steel plate, FIG. 10(B) is an X-X sectional view of (A), and FIG. 10(C) is a Y-Y sectional view of (A).

[0019]FIG. 11(A) is a plan view of a slip stopping part in which a through hole is opened, and FIG. 11(B) is an X-X sectional view of (A).

BEST MODE FOR CARRYING OUT THE INVENTION

[0020] Next, an embodiment of the invention is described with reference to the drawings. In the drawings, a construction machine (hydraulic excavator) 1 is constructed so that the upper surfaces of a cover 2 covering the upper surface of the construction machine body and a tool box 3 are formed as stepping surfaces on which a worker walks and steps during maintenance, and a slip stopper 4 to which the invention has been applied is used on these stepping surfaces.

[0021] The slip stopper 4 has a plurality of slip stopping parts 6 formed in a vertically and horizontally running pattern on a flat steel plate 5, and in the slip stopping parts 6, a concave portion 8 and drain channels 9 are formed in a protruding portion 7 that protrudes in the plate thickness direction from the upper surface 5 a of the steel plate 5 by shear planes 8 a, 9 a described later.

[0022] Namely, the protruding portion 7 is circular in a plan view and has a roughly arc-shaped section, and a roughly quadrilateral concave portion 8 is formed at the central portion of the upper surface side of this protruding portion 7, and the level of the groove bottom portion of this concave portion 8 is designed so as to be higher than the upper surface 5 a of the steel plate 5. Furthermore, four drain channels 9 that are shaped into concave grooves leading to the upper surface 5 a of the steel plate 5 from the concave portion 8 are formed radially, and the groove bottom portions of these drain channels 9 are formed to be inclines the levels of which are almost equal to the level of the groove bottom portion of the concave portion 8 at the concave portion 8 side, become almost equal to the level of the upper surface of the protruding portion 7 at the marginal section of the protruding portion 7 and become high at the concave portion 8 side and lower toward the marginal side of the protruding portion 7, whereby water or dirt is prevented from accumulating in the concave portion 8. On the other hand, at the lower surface side of the protruding portion 7, portions 8 b, 9 b that are the back surface sides of the concave portion 8 and the drain channels 9 protrude downward and become concave in a direction opposite to the upper surface side.

[0023] Herein, the inner circumferential surface of the concave portion 8 and the groove side surfaces of the drain channels 9 are formed by shear planes 8 a, 9 a which face almost perpendicularly to the upper surface 5 a of the steel plate 5 and have been half-blanked so as not to open a through hole in the steel plate 5. Furthermore, these shear planes 8 a, 9 a are sheared so that the upper edges are shaped acutely, that is, acute edges are raised.

[0024] To form the slip stopping part 6, after a first process in which a protruding portion 7 is formed by using the first and second punching die units 10, 11, a second process is carried out in which the concave portion 8 and the drain channels 9 are formed.

[0025] Namely, the first punching die unit 10 is for forming the protruding portion 7 on the steel plate 5, and comprises a punch assembly 12, a die assembly 13, and a striker 14. The punch assembly 12 comprises a punch 16 for forming a protruding portion, to be fitted in a guide hole 15 a opened in an upper base 15 in a manner enabling it to move up and down, a flange 18 integrally attached to the upper end of the punch 16 via a bolt 17, a punch head 20 integrally attached to the upper side of the flange 18 via a bored bolt 19, a support member 22 which is supported by a guide bolt 21 fixed to the upper base 15 in a manner enabling it to move up and down, and comes into contact with the flange 18 from below, and a spring 23 which presses the support member 22 upward, etc. The die assembly 13 comprises a die 25 for forming a protruding portion, fixed to a lower base 24, a stripper bolt 26 which is fastened to the die 25 so as to turn the head downward, a urethane spring 27 through which the stripper bolt 26 is inserted, upper and lower collars 28 and 29 through which the stripper bolt 26 is inserted while the collars are positioned at the upper side and the lower side, and an ejector plate 31 which is fixed to the upper collar 28 via an ejector bolt 54 and guided to the die 25 via a stopper bolt 30 in a manner enabling it to move up and down for a predetermined distance.

[0026] In the first punching die unit 10, while the striker 14 moves up, as shown in FIG. 5, the punch 16 is positioned at a moved-up position separated from the die 25 in a condition of sinking inside the guide hole 15 a of the upper base 15 because the support member 22 that has been retained at a predetermined position by the pressing force of the spring 23 is in contact with the flange 18 from below. Furthermore, the ejector plate 31 is positioned so that the upper end of the ejector plate 31 is at almost the same height as the upper end of the die 25 by the pressing force of the urethane spring 27.

[0027] When the striker 14 is moved down after the steel plate 5 is set between the punch 16 and the die 25 in a condition where the striker 14 is moved up, as shown in FIG. 6, the punch 16 moves down and projects downward from the guide hole 15 a, and a protruding portion 7 is formed on the steel plate 5 by being pressed by the punch 16 that has moved down and the die 25. At this point, the ejector plate 31 is moved down by being pressed by the punch 16 via the steel plate 5, however, in accordance with moving-up of the punch 16 after forming the protruding portion 7, the ejector plate moves up by the pressing force of the urethane spring 27 to separate the steel plate 5 from the die 25.

[0028] On the other hand, the second punching die unit 11 is for forming a concave portion 8 and drain channels 9 in the protruding portion 7 formed by the first punching die unit 11, and comprises, as in the case of the abovementioned first punching die unit 10, a punch assembly 32, a die assembly 33, and a striker 34. The punch assembly 32 of this second punching die unit 11 comprises, a punch guide 36 which is fitted in a guide hole 35 a opened in an upper base 35 in a manner enabling it to move up and down, a flange part 36 a which is integrally formed at the upper end of the punch guide 36, a stripper plate 38 which is fastened to the lower end of the punch guide 36 via a stopper bolt 37, a punch 39 for forming a concave portion and drain channels, to be inserted through the cylindrical hole portions 36 a, 38 a opened in the punch guide 36 and the stripper plate 38 in a manner enabling it to move up and down so that the upper end projects upward from the flange part 36 a, and a stripping spring 40 interposed between the upper end of the punch 39 and the flange part 36 a, a support member 42 which is guided by a guide bolt 41 fixed to the upper base 35 in a manner enabling it to move up and down, and comes into contact with the flange part 36 a from below, and a spring 43 which presses the support member 42 upward, etc. The die assembly 33 comprises a die 45 for forming a concave portion and drain channels, fixed to the lower base 44, a stripper bolt 46 that is the same as in the first punching die unit 10, a urethane spring 47, upper and lower collars 48, 49, and an ejector plate 50, etc.

[0029] When the striker 34 moves up, in the second punching die unit 11, as shown in FIG. 8, since the support member 42 retained at a predetermined position by the pressing force of the spring 43 is in contact with the flange part 36 a from below, the punch guide 36 is positioned at a moved-up position separated from the die 45 so that the stripper plate 38 sinks inside the guide hole 35 a opened in the upper base 35. The punch 39 sinks in the cylindrical hole portion 38 a of the stripper plate 38 due to the pressing force of the stripping spring 40. Furthermore, the ejector plate 50 is positioned so that the upper end of the ejector plate 50 is at nearly the same height as that of the upper end of the die 45 by the pressing force of the urethane spring 47.

[0030] When the striker 34 is moved down after the protruding portion 7 of the steel plate 5 is positioned between the punch 39 and the die 45 in a condition where the striker 34 moves up, the punch 39 and the punch guide 36 move down together first, and accordingly, the stripper plate 38 projects downward from the guide hole 35 a of the upper base 35 and comes into contact with the upper surface 5 a of the steel plate 5, whereby the steel plate upper surface 5 a is pressed by the stripper plate 38. Next, the punch 39 moves down alone and the punch 39 that has moved down and the die 45 form a concave portion 8 and drain channels 9 in the protruding portion 7. The inner circumferential surface of this concave portion 8 and the groove side surfaces of the drain channels 9 are formed by, as mentioned above, shear planes 8 a, 9 a that face almost perpendicularly to the upper surface 5 a of the steel plate 5 and have been half-blanked so as not to open a through hole in the steel plate 5. In this case, by setting the clearance between the punch 39 and the die 45 to zero, acute edges can be raised at the upper edges of the shear plates 8 a, 9 a.

[0031] Furthermore, in accordance with moving-up of the punch 39 after the concave portion 8 and drain channels 9 are formed, the stripper plate 38 and the ejector plate 50 act to separate the steel plate 5 from the punch 39 and the die 45 as in the same manner as the ejector 31 of the first punching die unit 10 mentioned above.

[0032] Furthermore, in this embodiment, the first and second punching die units 10, 11 are attached to the turret of a turret punch press that is not shown, and the steel plate 5 is supported on the table of the turret punch press, and the second process for forming the concave portion 8 and the drain channels 9 is carried out successively from the first process by moving the turret or the table for positioning.

[0033] In the abovementioned construction, at the slip stopping part 6, a concave portion 8 is formed at the central portion of the protruding portion 7 that protrudes in the plate thickness direction from the upper surface of the steel plate 5, and drain channels 9 shaped into concave grooves are formed radially from the concave portion 8 so as to lead to the upper surface 5 a of the steel plate 5, and these concave portion 8 and drain channels 9 are formed by shear planes 8 a, 9 a that face almost perpendicularly to the upper surface 5 a of the steel plate 5 and have been half-blanked so as not to open a through hole in the steel plate 5. The shear planes 8 a, 9 a can achieve an excellent reliable slip stopping effect because their protrusions become high from the steel plate upper surface 5 a according to the protrusion height of the protruding portion 7, and the upper edges are acute. In this case, the angle between the shear planes 8 a, 9 a and the upper surface of the protruding portion 7 becomes more acute as the inclination of the protruding portion 7 increases, and more acute edges can be raised at the upper edges of the shear planes 8 a, 9 a as this angle becomes more acute, whereby the slip stopping effect can be further improved.

[0034] In this construction, since the shear planes 8 a and 9 a have been half-blanked so as not to open a through hole in the steel plate 5, problems such that water or dirt entering inside the cover 2 or the tool box 3, blowing up of heated air from an engine, and noise diffusion to the outside can be prevented without the conventional double structure with a through hole opened, resulting in a significant cost reduction.

[0035] Furthermore, in this construction, since the drain channels 9 are formed to be inclines, the slip stopping effect can be prevented from being lost due to accumulation of water or dirt in the concave portion 8, cleaning can be easily carried out even if dirt or dust accumulates in the concave portion 8 or the drain channels 9, and furthermore, since the groove side surfaces of the drain channels 9 are also formed by shear planes 9 a, the abovementioned slip stopping effect can be further increased.

[0036] Thus, the slip stopping part 6 has a great slip stopping effect and does not open a through hole in the steel plate 5, and to form this slip stopping part 6, the second process for forming the concave portion 8 and the drain channels 9 by the second punching die unit 11 is carried out after the first process for forming the protruding portion 7 by the first punching die unit 10.

[0037] As a result, the protruding portion 7 can be formed to be sufficiently high, the stress to be applied to the steel plate 5 when shearing the protruding portion 7 by means of half blanking can be reduced, and acute edges can be raised at the upper edges of the shear planes 8 a, 9 a, whereby an excellent slip stopping effect can be achieved as mentioned above.

[0038] Industrial Applicability

[0039] The present invention can be widely applied in technical fields of a method and an apparatus for manufacturing a slip stopper for various footings requiring a device to prevent slipping, such as stepping surfaces of construction machines, floors, passageways, and stairs of building constructions, floors and steps of buses, trucks, and special vehicles, decks of railroad vehicles and ships, scaffolding at construction sites, etc. This invention can also be used for a location where a problem occurs if a through hole is opened therein, and is useful in a case where it is demanded to manufacture readily a slip stopper having a great slip stopping effect at low cost. 

What is claimed is:
 1. A method for manufacturing a slip stopper for a construction machine, wherein after a plurality of protruding portions are formed on a metal plate so as to protrude in the plate thickness direction, concave portions are respectively formed in the protruding portions by shear planes that face almost perpendicularly to the plate surface of the metal plate and have been half-blanked so as not to open through holes in the metal plate.
 2. An apparatus for manufacturing a slip stopper for a construction machine, comprising a first punching die unit for forming a plurality of protruding portions on the surface of a metal plate so as to protrude in the plate thickness direction, and a second punching die unit for forming concave portions respectively in the protruding portions formed by the first punching die unit by shear planes that face almost perpendicularly to the plate surface of the metal plate and have been half-blanked so as not to open through holes in the metal plate. 